TURBINE STRESS

MONITOR

Users’ Manual
&
Fatigue Calculations

For 500MW Thermal Power Plant, NTPC, Simhadri

The information contained in this document is the property of BHEL and is not
to be used for any purpose other than for it’s intended use.

BHARAT HEAVY ELECTRICALS LIMITED

Power Plant Dynamics and Simulation
Corporate R&D Division, Vikasnagar
Hyderabad 500093
 TABLE OF CONTENTS

SECTION 1 : USERS MANUAL

1.0 Introduction
2.0 User Screens
2.1 Status Display
2.2 Component Fatigue
2.3 Creep Fatigue
2.4 Low Cycle Fatigue
2.5 Stress Cycle Fatigue
3.0 Folders and Files
3.1 The ConfigFiles folder
3.2 The Backup folder
3.2.1 DataFiles
3.2.2 Fatigue Files
4.0 Taking Backup:
5.0 Installation

SECTION 2 : FATIGUE CALCULATIONS WRITEUP

1.0 Introduction :
1.1 Turbine Stress Monitoring (Tscmon)
1.2 Thermal Load
2.0 Input Parameters
3.0 Calculation Of Expended Life
3.1 Determination Of Low Cycle Fatigue
3.1.1 Delta T
3.1.2 Epsilon
3.1.3 Intermediate Stress Cycle And Full Stress Cycle
3.2 Accumulated Fatigue Due To Creep (Cf)
3.3 Determination Of Fatigue Life ( Rotor )
SECTION 1

Users’ Manual
 Turbine Stress Monitor
1.0 INTRODUCTION:

Turbine Stress Monitoring (TSCMON) software is a program which monitors, evaluates and
records the thermal stress of the turbine components. This software runs in an exclusive
dedicated computer viz. Turbine Stress Computer meant for the purpose.

Fig.1 Configuration of Turbine Stress Monitor

Turbine Stress
Controller
(ProControl PR05)

BK03

Turbine Stress Computer

2.0 User Screens

2.1 Status Display

The application opens with the Status Display screen. All the parameters obtained from
Turbine Stress Controller through the BK03 module are displayed in this screen.

In addition, ”Communication Healthy” is indicated by a lamp display which blinks in green

color to indicate communication with BK03 is OK. The same lamp blinks in red color to
indicate “Communication Failure”.

The Life Flag blinks in green to indicate the Life Calculations software is running properly. If
it blinks in red it means Life Calculations software is hanging.

A sample screen of Sattus Display is as follows:

On right clicking on one of the components a menu bar is displayed.
The options presented in case of Main Stop Valve, Main Control Valve and HP Casing are
as follows:
• Component Fatigue
• Creep Fatigue
• Low Cycle Fatigue

The options presented in case of HP Casing and IP casing are:

• Component Fatigue
• Creep Fatigue
• Low Cycle Fatigue
• Stress Cycle Fatigue

On clicking one of these options the corresponding page is displayed.

2.2 Component Fatigue

The Component Fatigue summarizes the Accumulated Low Cycle Fatigue and CF values in
the last two columns as shown
2.3 Creep Fatigue

The Creep Fatigue Matrix displays in a matrix form, the number of hours of operation of the
selected component for different temperature and pressure bands.
2.4 Low Cycle Fatigue

The Low Cycle Fatigue Matrix displays in a matrix form, the number of occurrences of
Strain (epsilon) of the selected component for different temperature bands.
2.5 Stress Cycle Fatigue

The Stress Cycle Fatigue Matrix displays in a matrix form, the number of occurrences of
Stress (Sigma) of the selected component for different temperature bands.
3.0 Folders and Files

The files required for the application are kept in the C:\TSCMON folder. This folder contains:

• TSCMON.exe which is the executable module

• Backup folder
• ConfigFiles folder.

3.1 The ConfigFiles folder contains required data for the particular project and should not be
disturbed.
The TSCSettings .INI file contains configuration information for COM port.

3.2 The Backup folder contains two more folders viz. DataFiles and FatigueFiles

3.2.1 DataFiles :

The DataFiles folder contains files with filename format as CurrentData_DD_MM_YYYY. One file
is created everyday. All the Plant variables required for Life Calculations are stored, as and
when there is any significant change in any parameter.
3.2.2 FatigueFiles

The FatigueFiles folder contains the following types of files:

Sno File Number File names Description

extensions of files
I .CF files 5 files HPCTPMAT.CF Creep Fatigue information
HPSTPMAT.CF Temperature Pressure Matrix
IPSTPMAT.CF
MCVTPMAT.CF
MSVTPMAT.CF

II .EPS files 5 files HPCKLAS.EPS Low Cycle Fatigue information

HPSKLAS.EPS Epsilon Matrix
IPSKLAS.EPS
MCVKLAS.EPS
MSVKLAS.EPS

III .LCF files 5 files HPCFAT.LCF Component Fatigue information

HPSFAT.LCF LCF for latest cycle +
IPSFAT.LCF Accumulated fatigue
MCVFAT.LCF
MSVFAT.LCF

IV .SIG files 2 files HPSKLAS.SIG Stress Cycle Fatigue

IPSKLAS.SIG Information of Sigma matrix

V .SCF files 2 files HPSFAT.SCF Stress Cycle Fatigue

IPSFAT.SCF Information of Sigma max and
min for latest cycle +
Accumulated Strain

VI .TXT files 5 files HPCLCF_MM_YYYY Details of Intermediate and Full

HPSLCF_MM_YYYY Cycle fluctuations for Epsilon
IPSLCF_MM_YYYY and Sigma
MCVLCF_MM_YYYY These files are created one per
every month
MSVLCF_MM_YYYY
HPSSCF_MM_YYYY
IPSSCF_MM_YYYY
4.0 Taking Backup:

The backup is maintained by the software in the Backup folder of TSCMON.

In order to be able to reconstruct data in case of machine or hard disk crash, it is

recommended to tack periodic backup of this Backup folder.

A CD Writer is provided on the machine with CD writing software. Backup may be taken for
individual units onto seperate CDs periodically by using the CD writing software. The latest
CD Backup will have to be used if there is a requirement of re-installation.

5.0 Installation

An Installation CD is provided which can be used for installation onto a new machine. The
CD contains following
• TSCMON folder
• SUPPORT folder
• Ini_2k.bat file
• Ini_XP.bat file

The Installation instructions are as follows.

1. Copy all files from support folder to system32 folder.

( Incase of XP c:\WINDOWS\System32; in case of 2000 c:\WINNT\System32
2. Copy 'tscmon' folder to c:/
3. Run ini_2k(for win2000) or ini_xp.bat(for winxp) file from cd.
4. Run mdac_typ.exe from support folder from CD.
5. Copy configFiles from CD backup for corresponding unit in C:\TSCMON\
6. Copy Latest Backup to C:\TSCMON\
 THIS PAGE

INTENTIONALLY

LEFT BLANK
SECTION 2

Fatigue
Calculations
 TURBINE STRESS COMPUTER (TSC)

1.0 INTRODUCTION :

The Turbine Stress Controller (TSC) is an intelligent supervisory system that checks the
transient thermal loads on the turbine components during all phases of operation . It
enables monitored operation of the turbine in three startup modes viz. Cold , Warm and
Hot . During operation in any operation mode, which are be selected by the monitoring of
temperature of HP Casing , thermal fatigue data of the monitored components is
continuously evaluated and recorded.

In addition to turbine component monitoring, other tasks, for e.g. computation and display
of permissible temperature and load guidance, accumulated fatigue and residual life
analysis, long-term storage of data for the monitored turbine components and formation of
the turbine startup criteria .

Based on the requirements, the functions of the turbine stress controller are divided
between two sub-systems.

The Turbine Stress Control subsystem which implement functions that have direct effects
on the process are executed by the processor module PR05 of Procontrol system situated
in cabinet CJJ01 .

The extensive and highly accurate computations and long-term data storage operations
for the accumulated fatigue and life computations are executed by a software which runs
in the Turbine Stress Computer.

1.1 TURBINE STRESS MONITORING (TSCMON) :

Turbine Stress Monitoring (TSCMON) software is a program which monitors, evaluates

and records the thermal stress of the turbine components. This software runs in an
exclusive dedicated computer viz. Turbine Stress Computer meant for the purpose.
 The TSCMON software is an application in microsoft windows environment, which runs in
a dedicated PC. The measured data used for computing the stress parameters are
obtained from the Turbine Stress Controller (TSC).

The Turbine Stress controller is implemented in the PRO5 module of ProControl

hardware.

The TSCMON software performs the stress monitoring functions for the following
components.
1. Main Stop Valve (MSV)
2. Main Control Valve(MCV)
3. High Pressure Turbine Casing (HPC)
4. High Pressure Turbine Shaft (HPS)
5. Intermediate Pressure Turbine Shaft (IPS)

1.2 THERMAL LOAD :

When the steam temperature in the interior of the turbine change suddenly, the metal
temperatures in the various turbine components follow with a time lag. As a result, free as
well as restricted strains occur in the turbine components. The latter causes materials
stresses of thermal loads, which lead to corresponding accumulated fatigue of the
material.

During normal operation of the turbine, the loads occur cyclically in alternating directions (
compressive and tensile stress ) due to the heating and cooling in regions of assembly
component surfaces exposed to steam and also in the shaft axis.

The determining factors for the magnitude of the temperature differences in the assembly
components and thus for the thermal loads are
• the time sequences of the steam temperature changes
• the heat transfer from steam to metal
• the geometric shape and material properties of the assembly components
2.0 INPUT PARAMETERS

The following input parameters are required for performing the calculations to determine
the stress of the components.
1. Temperature before MSV
2. Pressure before MSV
3. Temperature in IPC
4. Pressure before LPB
5. Pressure in HPC
6. Surface Temperatures for all the 5 components viz (MSV,MCV,HPC,HPS,IPS)
7. Mean Integral Temperature i.e. temperature at 50% depth for all components
viz(MSV,MCV,HPC,HPS,IPS)
8. Mean Integral Temperature of shaft for HPS & IPS.
9. Axial temperature of shaft for HPS & IPS.
10. Speed actual
11. Load Actual.

The Mean Integral Temperature values (Tm ) for MCV,MSV and HPC are as measured from
the sensors. The Tm value at the groove of the rotor where the blades are inserted in the
rotor, termed as Tm-groove is also used in Stress calculations. It is not possible to
measure Tm for the rotor. Similarly, it is also not possible to measure the axial temperatures
along the rotor.

These values are simulated using a shaft simulation program module which estimates the
Tm value based on the measured values, geometry and material of the component.

3.0 CALCULATION OF EXPENDED LIFE

The material fatigue values of the turbine components consist of 3 parts.

1. Accumulated Low Cycle Fatigue(LCF)
2. Accumulated Creep Fatigue(CF)
3. Accumulated Stress Cycle Fatigue(SCF)
The accumulated fatigue computations performed as applicable for the individual turbine
components are listed below

LCF CF SCF
Main stop valve MSV 9 9
Main Control valve MCV 9 9
HP Casing HPC 9 9
HP Shaft HPS 9 9 9
IP Shaft IPS 9 9 9

3.1 DETERMINATION OF LOW CYCLE FATIGUE

The Accumulated Low Cycle Fatigue is the accumulated fatigue due to cyclic strain.
LCF occurs at the steam side surface i.e on the inner surface. in case of casing and on
the outer surface in case of the shaft.

3.1.1 Delta T

The basis for computation of the LCF is the occurrence of Temperature difference, ∆T
between Surface Temperature Ti and Mid Temperature Tm.
∆T = Ti - Tm

During heating, when steam temperature increases from a given steady state, Ti is
greater than Tm and ∆T is positive. On the contrary, when steam temperature
decreases from a given steady state, Ti is less than Tm and ∆T is negative.

3.1.2 Epsilon

The inhibited Thermal Strain which occurs during thermal changes is termed as
Epsilon and is a function of the geometry, material and temperature difference.

ε = αk [β / ( 1-ν)] ∆T
where
 αk = Stress Concentration factor
describing the geometry and material characteristics
β = material expansion coefficient
ν = Poissons Ratio

3.1.3 Intermediate Stress Cycle and Full Stress Cycle

When the ∆T and Epsilon values are plotted with time, the fluctuations in Epsilon follow
fluctuations in ∆T. Different ‘delta epsilon’ values of the same sign, occurring
successively in time, are defined as an intermediate load cycle or Intermediate Stress
Cycle (ISC).

One Intermediate Stress Cycle comprises of a peak in Epsilon and two minima , one
preceding and one succeeding the Epsilon peak.

When the Epsilon value changes sign, a zero crossing is said to have occurred. Three
successive zero crossings constitute a full cycle.

A main load cycle or Full Stress Cycle (FSC) is the time sequence of one positive and
one negative delta epsilon value.

The maximum value which occurs in a Full Stress Cycle is εmax and the minimum
value which occurs in a Full Stress Cycle is εmin. These are illustrated in detail in Fig.
1.
 Epsilon
εmax

Time
ISC1

εmin ISC2

Zero crossing
FSC

ISC - Intermediate Stress Cycle

FSC - Full Stress Cycle ( thermal load cycle)

Fig 1. Intermediate Stress Cycle and Full stress

The curves for values of ε versus no of cycles to crack initiation (n) are available for
individual components.
 Lower
∆ε Higher

n1 n2 No of cycles to crack initiation

Fig 2. ∆ε Vs No of cycles to crack initiation

It can be seen from the above curves that for a given thermal strain cracking can be
initiated for less number of cycles (n1) at higher temperatures, while it takes more
cycles (n2), at lower temperatures.

The data for number of cycles to crack initiation at a temperature called Transition
temperature (Tr) is available for different equipment. The same is extrapolated, by the
software for the operating temperature.

The stress due to intermediate fluctuations as well as the thermal load cycle makes
contribution to the total low cycle fatigue. The full impact of low cycle fatigue can be
determined only at the end of a thermal load cycle. For this reason, the temperature
differences, their extremes and the absolute temperatures occurred, are stored as and
when they are sampled. The software detects the extreme maximum and minimum
values of ε and zero crossings of ε.
As soon as thermal cycle comes to an end, the stored data are evaluated. The
maximum and minimum temperature differences are used to calculate the inhibited
thermal expansion. The thermal strain during a thermal load cycle ∆εmax is derived from
extreme absolute values as follows
∆εmax= εmax - εmin
This value of ∆εmax is used to calculate the associated number of cycles to crack
initiation from the curves available. The same evaluation is also performed for
intermediate stress cycles, if there are any significant intermediate fluctuations. The low
cycle fatigue increment ∆En is obtained as
∆En = 1 / n
Where n=number of cycles to crack initiation.

The low cycle fatigue over one thermal load cycle is sum of intermediate stress cycle
and full stress cycle fatigues. When the main load cycle is completed, the accumulated
fatigue portions of main and intermediate load cycle for this load cycle are added to the
total accumulated fatigue of the turbine component.
∆En= ∆En (FSC) + ∆En (ISC1) + ∆En (ISC2) +………..

The accumulated low cycle fatigue is

En =∑ En.

This evaluation is performed for all the components. The low cycle fatigue and
evaluated data are stored. The low cycle fatigue information is displayed in the form of
a matrix.

The column of the matrix represents different temperature bands and the rows

represent different ε bands. The units of ε are promal represented as ‘.%’ This is

defined as the value of epsilon derived as explained above multiplied by 1000. The
number of occurrences of ε epsilon(strain) appear as elements in this matrix display.
The fatigue display page shows the data for the latest load.
 3.2 ACCUMULATED FATIGUE DUE TO CREEP (CF)

The design of assembly components which are exposed to high temperature in

operation is generally based on time dependent strength values known as “Rupture
Strength “. The assembly components are dimensioned for a specified operating
temperature and thus for a specified load i.e., Warning point.

If operating temperature and load are constant over the operating period, the
accumulated fatigue can be computed as the ratio of the “ total operating time “ to the
until failure “ or the designed life time. When this ratio reaches the value of 100%,
detailed inspection of the assembly of the assembly component is to be carried out.
However, in general, operating temperature and operating loads change during
operation. The total accumulated fatigue due to time dependent creep can therefore be
represented only as the sum of individual portions corresponding to various time
intervals.

3.3 DETERMINATION OF FATIGUE LIFE ( ROTOR )

The method of determination of accumulated Fatigue due to Cyclic Stress (Stress

Cycle Fatigue - SCF) in the shaft axis is described below.

For the shaft interior, as for the casing, the accumulated fatigue portions from the
startup processes and steady-state operation are totaled cumulatively over the total
operating time. If the permissible total accumulated fatigue is exceeded, detailed
assembly component inspections are to be carried out.

The material properties as well as the deficiencies of the forging that were within
testing accuracy during the receiving inspection and that must be interpreted as
incipient cracks , are included in the accumulated fatigue analysis by application of the
methods of “ linear elastic fracture mechanics “.